Combination systems and related methods for providing power, heat and cooling

ABSTRACT

A combined heat, cooling and power system is configured to generate energy as well capture a large percentage of energy that would otherwise be lost using components, including heat transfer components, embedded within a vessel to transfer energy in the form of heat to liquid within the vessel.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/974,679 filed May 8, 2018 (“'679 application) which is acontinuation-in-part of U.S. application Ser. No. 15/621,711 filed Jun.13, 2017 (the “'711 application”) and claims the benefit of priority ofU.S. Provisional Patent Application Ser. No. 62/349,346 filed on Jun.13, 2016 (“'346 application”), U.S. Provisional Patent Application No.62/419,188 (“'188 application”) having a filing date of Nov. 8, 2016,and the '711 application. This application incorporates by referenceherein the entire disclosures of the '679, '346, '188 and '711applications as if they were set forth in full herein.

INTRODUCTION

A continuing challenge is to economically provide energy while yetreclaiming various aspects of the energy development such as heat. Yetanother challenge is to reduce carbon emissions when operatingcombustion engines to produce energy such as electrical energy.Oftentimes, heat generated by combustion within the engine is wasted.Furthermore, challenges such as packaging and engine efficiency remainas design concerns in the development of combined heat and powersystems.

Other challenges include complying with the relevant EPA or otherenvironmental regulatory references when providing in-home orin-dwelling engines used to power a combined heat and power system.Accommodating all of these concerns within one energy unit remains anongoing challenge.

Accordingly, it is desirable to provide for systems, devices and relatedmethods that accommodates the above concerns within a single system.

SUMMARY

The above-referenced challenges are resolved by embodiments of thepresent invention. Unique systems, devices and related methods thatconvert mechanical energy into electricity and produce heat in threeways: through the engine exhaust stream, through the engine coolantstream, and by radiant or convective heat.

An embodiment of the present invention may be directed at a combinedheat, cooling and power system that comprises: (i) an energy generationsub-system comprising a replaceable engine connected to a plurality ofgenerators and a turbo-generator, the sub-system operable to generateelectricity and exhaust gases, and provide energy to an energy storagesub-system, and a vessel for storing liquid, the liquid heated by wasteheat from the engine; (ii) an energy distribution sub-system comprising,coils operable to circulate heated coolant received from the energygeneration sub-system, and, fans operable to direct air over the coilsto heat the directed air, and operable to distribute the heated air; and(iii) an energy storage sub-system operable to receive and store theenergy from the energy generation sub-system.

In an embodiment, the energy storage sub-system may comprise a batteryoperable to discharge stored energy to the energy distributionsub-system or to an electrical utility grid. Further, theturbo-generator may be operable to receive exhaust gases from the engineand convert the exhaust gases to electricity, yet further, theturbo-generator may be configured at a position between the engine and acatalytic converter to protect the converter from extremely hightemperatures emitted from the engine.

In an embodiment, the exemplary system may comprise the catalyticconverter embedded in the vessel, where the converter may be configuredto be positioned within a distance from the engine, where a temperatureof the exhaust gases optimizes the operation of the catalytic converter,and, still further a muffler embedded in the vessel and operable toreduce a level of sound from the engine and the exhaust gases.

To capture heat that may otherwise be wasted or escape, the system mayfurther comprise an exhaust heat exchanger that may operable to transferheat within the exhaust gases to liquid within the vessel, and a coolantheat exchanger operable to transfer heat from coolant to the liquidwithin the vessel.

In yet another embodiment, a similar system may further comprise (i) anair intake section configured to be positioned so that external air fromoutside the energy generating sub-system may be drawn into a cowling andover the engine and generators in order to cool the engine and pre-heatthe air, and (ii) thermo-acoustic insulation configured inside thecowling, the insulation operable to prevent sounds emanating from insidethe cowling from escaping the cowling.

In addition to the systems described above, the present inventionprovides related methods, such as a method for providing heat, coolingand power that comprises: generating electricity and exhaust gases froman engine, and providing energy to an energy storage sub-system (e.g., abattery); storing a liquid, heated by waste heat from the engine, in avessel; circulating heated coolant through coils and directing air overthe coils to heat the directed air; distributing the heated air; andreceiving and storing the energy in the energy storage sub-system.

Such an exemplary method may further comprise discharging the storedenergy to an energy distribution sub-system or to an electrical utilitygrid as needed or desired.

A further method may comprise one or more of the processes justdescribed and, in addition, receiving exhaust gases and converting theexhaust gases to electricity using a turbo-generator configured at aposition between the engine and a catalytic converter, where thecatalytic converter may be embedded in the vessel at a position where atemperature of the exhaust gases optimizes the operation of thecatalytic converter. Yet further, in addition to embedding a converter,such a method may comprise embedding a muffler in the vessel to reduce alevel of sound from the engine and the exhaust gases.

To capture heat that is derived from operation of an engine, among othercomponents, that may otherwise be wasted or escape the method mayfurther comprise transferring heat within the exhaust gases to a liquidwithin the vessel and transferring heat from coolant to the liquidwithin the vessel.

Finally, but without limitation, yet another method may combine one ormore the processes described above along with (i) positioning an airintake section so that external air is drawn over the engine in order tocool the engine and pre-heat the air, and (ii) preventing soundsemanating from inside a cowling from escaping the cowling.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an exemplary combined heat, cooling and power systemin accordance with an embodiment of the present invention.

FIG. 2 illustrates application of reclaimed heat of the combined heat,cooling and power system of FIG. 1 in accordance with an embodiment ofthe present invention.

FIG. 3 illustrates yet another exemplary combined heat, cooling andpower system in accordance with an embodiment of the present invention.

FIG. 4 depicts an exemplary combined heat, cooling and power system thatcomprises energy storage and distribution capabilities.

FIG. 5 depicts a cross-sectional view of an exemplary energy generationsub-system of an exemplary combined heat, cooling and power system inaccordance with an embodiment of the present invention.

FIG. 6 depicts an enlarged view of a portion of the exemplary energygeneration sub-system shown in FIG. 5 in accordance with an embodimentof the present invention.

FIG. 7 is a cross-sectional view of two exemplary opposed pistons withinan associated cylinder of an exemplary engine in accordance with anembodiment of the present invention.

FIG. 8 illustrates various piston faces in accordance with embodimentsof the present invention.

FIG. 9 illustrates a perspective cross-section of the combustion chamberand piston face in an exemplary engine in accordance with an embodimentof the present invention.

FIG. 10 illustrates two exemplary cylinders in accordance withembodiments of the present invention.

FIG. 11 illustrates two pistons at top dead center, in accordance withan embodiment of the present invention.

FIG. 12 illustrates a geared drive system in accordance with anembodiment of the present invention.

FIG. 13 illustrates a geared drive system in accordance with anembodiment of the present invention.

To the extent that any of the figures or text included herein depicts ordescribes dimensions, sound levels, power levels, efficiencies or otheroperating parameters it should be understood that such information ismerely exemplary to aid the reader in understanding the embodimentsdescribed herein. It should be understood, therefore, that suchinformation is provided to enable one skilled in the art to make and usean exemplary embodiment of the invention without departing from thescope of the invention.

It should be understood that, although specific exemplary embodimentsare discussed herein, there is no intent to limit the scope of thepresent invention to such embodiments. To the contrary, it should beunderstood that the exemplary embodiments discussed herein are forillustrative purposes, and that modified and alternative embodiments maybe implemented without departing from the scope of the presentinvention. Exemplary embodiments of systems, devices and related methodsfor providing power, heat and cooling are described herein and are shownby way of example in the drawings. Throughout the following descriptionand drawings, like reference numbers/characters refer to like elements.

It should also be noted that one or more exemplary embodiments may bedescribed as a process or method. Although a process/method may bedescribed as sequential, it should be understood that such aprocess/method may be performed in parallel, concurrently orsimultaneously. In addition, the order of each step within aprocess/method may be re-arranged. A process/method may be terminatedwhen completed and may also include additional steps not included in adescription of the process/method.

As used herein, the term “and/or” includes any and all combinations ofone or more of the associated listed items. As used herein, the singularforms “a,” “an” and “the” are intended to include the plural form,unless the context and/or common sense indicates otherwise.

As used herein, the term “embodiment” and/or “exemplary” refers to anexample of the present invention.

Embodiments of the present invention include a four-stroke,opposed-piston engine to provide energy from the thermo-dynamic transferof heat energy created during the operation of the engine. Although notnecessarily so limited, an exemplary engine may be a four-stroke opposedpiston engine that utilizes a fuel other than diesel, such as gasoline,propane, or natural gas, for example. Certain efficiencies are realizedwith the use of an opposed-piston configuration, particularly when afour-stroke engine is employed. It has been found that packagingefficiencies are improved, thereby resulting in a more-compact energyunit. Further, it has been found that a four-stroke opposed pistonengine is compliant with pertinent environmental regulations of the EPA.

Referring to FIG. 1, an energy recovery system 10 may include an engine26 that produces heat in both the exhaust stream and in a coolantstream, the features of which may be described in more detail in the'711 application incorporated by reference herein. A housing 20 containsa first pressure vessel 12 containing a first fluid or liquid 14, suchas water. A second pressure vessel 16 also contains a second fluid orliquid 18 such as water. The second vessel 16 may be a boiler formedsuch as described in U.S. Pat. Nos. 8,763,564 or 9,303,896, for example,the teachings of which are herein incorporated by reference as if fullystated. The first vessel or boiler 12, which in one embodiment isessentially formed as a hot water tank in a known manner, is surroundedby the second vessel 16, and is actually immersed within the fluid 18 ofthe second vessel 16. The second vessel 16 or hot water storage tank,may be formed as a hot water tank in a known manner, and contains acold-water inlet 22 and a hot water outlet 24. An exemplary engine 26,such as a four-stroke opposed piston engine as described below but notrestricted to that design, is also contained within the housing 20 butnot within either pressure vessel 12, 16, and provides combustion energyto produce electricity. At least one generator 28 is combined with theengine 26 in a known way, and when combined forms an exemplary “genset”26/28, as schematically shown in FIG. 1. In the embodiment depicted inFIG. 1 the genset comprises a dual generator 26/28 in accordance withthe present invention. It has been found that the efficiencies presentedby the novel gensets 26/28 described herein provide synergisticefficiencies with regard to recovering waste heat through the presentenergy recovery system, environmental advantages, and packagingefficiencies.

In accordance with embodiments of the present invention, the engine 26also produces waste heat that is directed from the engine 26 through anengine exhaust vent or duct during operation of the engine 26, asexhaust 26 c. A first heat exchanger 30 is configured within the firststorage tank/pressure vessel 12 and fluidly communicates with the engine26 whereby engine exhaust 26 c is directed from the engine 26 throughthe first heat exchanger coil 30 a as shown in FIG. 1, and then out avent 40 from the housing 20. The first heat exchanger coil 30 a may beformed from a thermally conductive material such as a metal, stainlesssteel for example, that thermally conducts heat into the fluid or waterof the first storage tank/pressure vessel 12. A second heat exchanger 32is configured within the second storage tank/pressure vessel 16, andfluidly communicates with the engine whereby engine coolant 32 b isdirected through the second heat exchanger coil 32 a. The second heatexchanger coil 32 a may be formed from a thermally conductive materialsuch as a metal, copper or brass for example. As shown in FIG. 1, acompressor 34 is connected to a coolant outlet 26 a and a coolant inlet26 b on the engine, such that heated coolant 36 may be pumped from theengine 26, compressed and further heated, and then passed through thesecond heat exchanger 32 within the second pressure vessel 16. As thecoolant passes through the second heat exchanger, the coolant is cooledto transfer heat to the second fluid 18, water, or liquid within thesecond pressure vessel 16. Once the coolant 36 has travelled through thesecond heat exchanger 32, and prior to the coolant 36 being reintroducedinto the engine 26, the coolant 36 is passed through an expander valve38 to thereby expand the coolant 36 to an even cooler state as itreenters the engine 26 through coolant inlet 26 b. Also shown is a hotfluid exit 23 from vessel 16 and a cooled fluid inlet 27 to vessel 16,representing a closed loop to a furnace and associated heat exchanger,for example. Accordingly, the present system recovers heat from both theexhaust and coolant systems of the engine.

Unless otherwise stated herein, such as with the details of thefour-stroke opposed-piston engine or with the details of the heatexchangers 30 and 32, the Combined Heat and Power (CHP) system shown inFIG. 1 may be constructed as known in the art. Accordingly, U.S. Pat.Nos. 9,617,897, 9,097,152, 6,823,668, 7,021,059, and 7,574,853 areinstructional and are herein incorporated by reference in theirentireties. Further, U.S. Patent Publication Nos. 2016/0194997,2009/0205338, and 2013/0247877 are instructional and are hereinincorporated by reference in their entireties. Finally, EP2503110 and WO2011/028401 are also instructional, and are herein incorporated byreference in their entireties.

As shown in FIG. 1, the exhaust from the first heat exchanger is ventedfrom the boiler or first vessel 12 through a boiler exhaust. As thewater is heated within the water storage tank or first vessel 12, hotwater 14 is pumped out to provide hot water for a variety ofapplications, and cold makeup water 13 is introduced into the waterstorage tank or first vessel 12. As also schematically shown in FIG. 1,a temperature controller 15 may control the temperature of the water 14in the hot water tank 12, and in the boiler 16. Accordingly, theoperation of the engine may be coordinated with the temperature controlsystem by increasing or decreasing the engine operating cycles/minute,respectively. An outer housing 44 is preferably formed about thecombined heat and power system 10, thereby forming a soundproofenclosure.

In an embodiment, it will be appreciated that an exhaust conduit 527 e(see FIG. 7) of the engine 26 and the heat exchange coil 32 a may beproximate to each other to optimize convection and maximize heatrecovery through heat transferred from the engine exhaust to the fluid18 within the second pressure vessel 16 (see FIG. 3).

As also schematically shown in FIG. 1, the combined system 10 maycontain a suspension or dampening system 42 to mitigate the effects ofthe vibration of the engine 26 in the home or office for example.Related thereto, vibration-resistant couplings for the intake, radiator,exhaust, and fuel supply of the engine 26 may also be integrated intothe dampening system 42 as schematically shown in FIG. 1.

Referring now to FIG. 2, there is depicted an exemplary combined heat,cooling and power system 210 that is operable to provide electricitythat may be used to power various equipment 250 around a dwelling orhouse 200, including driveway 200 a and a greenhouse 200 b. As alsoshown, hot water from the hot water tank 212 may be used to heat thedwelling 200 through radiant floor heaters 220, and/or to augment theheat provided by a furnace 222 through heat exchange at the furnace 222,and/or to heat a pool (not shown), among other hot water applications,including supplying heat that can be used to supply hot water throughoutthe house 200, for example. Other energy collectors, such as solarpanels 214 that provide photovoltaic energy, wind turbines 216 thatprovide rotary power, and so forth may be integrated to form a totalenergy storage system.

In an embodiment, excess energy from the engine/generator or genset226/228, the solar panels 214, and the wind turbine 216 may be stored ina battery pack 218. Furthermore, excess energy may be sold back to theexisting power grid 240 as needed.

Referring now to FIG. 4, there is depicted an exemplary, combined heat,cooling and power system 100 in accordance with an embodiment of theinvention.

As depicted the system 100 may include a plurality of sub-systems, suchas an energy generation sub-system 101, an energy distributionsub-system 103 and an energy storage sub-system 104. In an embodiment,the energy distribution sub-system 103 may comprise an air handlingsub-system while the energy storage sub-system 104 may comprise abattery, for example (e.g., exemplary capacity 6 kilowatts to 20kilowatts).

In an embodiment, the energy generation sub-system 101 may be operableto generate energy through the operation of an engine describedelsewhere herein as well as in the '711 application. In an embodiment,the energy generated by the sub-system 101 may be used to generate power(e.g., electricity), and/or heat water, for example. Further, asexplained in more detail herein, the sub-system 101 may be operable tocapture or re-capture (collectively “capture”) some of the energy usedto generate power, and heat water, for example.

As depicted, provided the energy generation sub-system 101 has aconnected energy source (e.g., natural gas), the sub-system 101 maygenerate electricity and provide the electricity to a dwelling or house,such as dwelling 200 in FIG. 2, In addition, sub-system 101 may beoperable to provide energy to the energy storage sub-system 104 in orderto charge or re-charge (collectively “charge”) the sub-system 104. Uponreceiving the energy from sub-system 101, the sub-system 104 may beoperable to store the energy and, when desired, discharge the storedenergy at a later time to provide power to sub-system 103, for example,or back to an electrical utility grid.

In an embodiment, the energy distribution sub-system 103 may be operableto function in combination with, or independently of, the sub-system101.

For example, in one scenario the energy generating sub-system 101 maycomprise an engine 128 connected to power a plurality of generators 128a,b and a turbo-generator 128 c (see FIG. 5) operable to generateelectricity that may be provided to a house or dwelling 200, forexample, shown in FIG. 2. However, as noted elsewhere herein, as theengine 128 (and generators to some extent) is operating it alsogenerates a substantial amount of heat that, in traditional systemswould not be used (i.e., it would be wasted). In embodiments of theinvention, such waste heat may be captured and used to heat a liquid(e.g. water) stored within a hot water storage tank or vessel 120 (seeFIG. 5) within sub-system 101 or be further provided to the energydistribution sub-system 103 to provide heated air to the dwelling orhouse 200.

In more detail, and as explained elsewhere herein, heat in the form of(i) exhaust gases output from the engine 128 upon burning an energysource and (ii) heated coolant may flow away from the engine 128 and itssurrounding area and eventually be fed to the vessel 120 (see FIG. 5)and sub-system 103. Thus, as explained in more detail elsewhere, heatthat would normally be lost is captured and used to heat water in thevessel 120, and provide heat to the dwelling or house 200, among otherthings.

In an embodiment, the temperature of vessel 120 may be monitored bytemperature and pressure controls (not shown in figures) to ensure thatthe temperature of the vessel 120 does not rise above a certain variablethreshold. In one example, such a variable threshold may comprise atemperature between 140° F. and 160° F.

In an embodiment, the controls may be operable to determine that thetemperature of the water 120 a within the vessel 120 is approaching orat a certain vessel threshold. Accordingly, the controls may sendsignals to a pump 108 a and by-pass valve 108 b (see FIG. 4) to open theby-pass valve and to direct heated coolant within piping 132 (see FIG.5) that would otherwise flow through water 120 a within vessel 120 tosub-system 103 via piping 108 c. Thus, by re-directing the heatedcoolant away from the vessel 120, the water within vessel 120 will beginto cool.

Upon receiving the heated coolant via piping 108 c, the sub-system 103may be operable to direct the heated coolant within piping 108 c tocoils 103 a. The coils 103 a are operable to circulate the heatedcoolant, and as the coolant is circulating, fans 103 b within thesub-system 103 may be operable to direct air over the now heated coilsto cool the coils and the coolant inside the coils. Conversely, theheated coolant (e.g., water) inside the coils heats the air flowingacross the coils.

In an embodiment where the dwelling or house 200 desires heating, thenow heated air that was directed over the coils may be forced, throughthe operation of fans 103 b out of the sub-system 103 into conduits orother ventilation equipment to be distributed throughout the house ordwelling 200.

Thus, in this embodiment, the heat within the coolant that is sent tothe sub-system 103 can be captured and distributed by the sub-system 103to further warm the house or dwelling 200. However, in the event thatthe dwelling or house 200 is not in need of heated air, the heated airmay be discharged to the exterior of the dwelling or house 200 via meansknown in the art.

Yet further, as indicated above the heated coolant may traverse throughcoils 103 a and be cooled by the air flowing across the coils 103 a. Inan embodiment, the now cooled coolant may be output from the sub-system103 via output piping 107 and sent to (i.e., returned to) the sub-system101 and, particular, sent to the vessel 120 and piping 132 at a reducedtemperature (e.g. 100° F.). In FIG. 4, the sub-system 103 is depicted asincluding a pump 105 that may be operable to apply a pressure to thecooled water exiting the sub-system 103 via piping 107 so as to returnthe water to the sub-system 101 under an acceptable pressure.

In the above scenarios, the sub-systems 101,103 work in combination to,for example, control the operating temperature of the vessel 120, and toprovide energy (heat) from the vessel 120 that can be distributed to thedwelling or house 200 by the sub-system 103.

In alternative embodiments, each of the sub-systems 101, 103 may operateindependently of one another.

For example, sub-system 103 may comprise temperature controls 103 c thatare operable to control the “on” and “off” operation of sub-system 103independent of the operation of sub-system 101. Said another way,controls 103 c may be operable to control whether sub-system 103provides forced heated air to the dwelling or house 200. In more detail,in one embodiment the controls 103 c may comprise sensors (not shown infigures) operable to detect the temperature of the air within dwellingor house 200. If the temperature detected by the sensors falls below adwelling threshold temperature (e.g., 65° F.), then the sensors may sendsignals to the controls 103 c that, in turn, send signals to the fan(s)103 b to turn the fans “on” and force heated air into the airdistribution system of the dwelling or house 200 to warm the house, forexample. Conversely, once the temperature of the air within the dwellingor house 200 detected by the sensors rises to meet, or exceed, adwelling threshold (the same or a different threshold), then the sensorsmay send signals to the controls 103 c that, in turn, send signals tothe fans 103 b to turn the fans “off” and which prevents heated air fromentering the air distribution system of the dwelling or house 200. Inthe scenario just described, the sub-system 103 operates independentlyof the subsystem 101 because its operation is not dependent upon theoperation of the sub-system 101 (e.g., not dependent upon thetemperature of the vessel 120).

Yet further, in an embodiment, when sub-system 103 is operating but theengine 128 and generators 128 a,b of sub-system 101 are not operating,the energy storage sub-system 104 may be operable to provide energy(e.g. electricity) to the sub-system 103 in order to power the fans 103b while the vessel 120 via piping 108 may be operable to provide heatedwater to coils 103 a of sub-system 103. Accordingly, fans 103 b mayoperate to force air over coils 103 a to provide heat to the dwelling orhouse 200.

The scenarios above are just of the many possible scenarios were thesub-systems 101,103 work in combination or independently of one another.

Referring now to FIG. 5 there is depicted a detailed view of anexemplary, energy generating sub-system 101 according to an embodimentof the invention. As shown, the energy generating sub-system 101 maycomprise the aforementioned engine 128 and connected generators 128 a,b,where each generator 128 a,b may be operable to generate energy in theform of electricity. The sub-system 101 may also include an additionalgenerator—turbo-generator 128 c—along with muffler and catalyticconverter unit 142, storage vessel 120, exhaust heat exchanger 130 (e.g.coils), coolant heat exchanger 132 (e.g., coils), intake air filtrationunit 113 b, and thermo-acoustical insulation 144 among other elements.In an embodiment, the muffler and catalytic converter unit 142, exhaustheat exchanger 130 and coolant heat exchanger 132 may be embedded withinthe vessel 120 in order to transfer heat from such components to liquid(e.g., water) inside the vessel 120 in order to capture energy in theform of heat from operation of the engine 128

Exemplary details of the structure, features and functions of the engine128 is set forth elsewhere herein as well as in the '711 application.Presently the discussion that follows will focus on the operation of theengine 128 in combination with the other elements of the sub-system 101.However, before continuing it should be noted that in embodiments,“quick connect/disconnect hardware” (not shown in figures) may beincluded within sub-system 101 to facilitate easy removal of the engine128.

In more detail, in one embodiment the engine 128 may be attached to atray by means of pins (not shown in figures) operable to slide out tofacilitate complete removal of the engine 128 when service requires thatwork be performed that is beyond what is possible in the field. Inaddition to these methods, wiring harnesses connected to the engine 128or the generators 128 a,b may comprise a pin-and-socket configurationthat function to be easily separated by an individual in the field usingexisting tools. The combination of these features results in an engine128 that can be replaced within hours, for example, when necessary.

In an embodiment, during operation the engine 128 and generators 128 a,bmay be operable to produce “waste” heat in the form of an exhaust gases(hereafter referred to as “exhaust”) that is directed from the engine128 to an exhaust pipe 121 and eventually to turbo-generator 128 c.Further, additional “waste” heat may be created within and on thesurface of the engine 128. In embodiments, the sub-system 101 may beconfigured to capture all sources of waste heat.

Turning first to the exhaust, in an embodiment the turbo-generator 128 cmay be operable to (i.e. function to) receive the exhaust and convertthe exhaust to an additional electricity amount (e.g., 1-2 kilowatts)over and above the electricity generated by generators 128 a,b.

In an embodiment, the turbo-generator 128 c may be configured to belocated at the output of the exhaust piping 121, substantially close tothe output of the engine 128, in order to maximize the conversion ofexhaust from the engine 128 into electricity. Accordingly, the length ofthe exhaust piping 121 may be configured to be a length that allows forsuch maximized conversion. In an example, the length of the exhaustpiping 121 may be (e.g., 1 to 3 inches).

In embodiments, the turbo-generator 128 c may be further configured tobe positioned at a location to convert exhaust energy into electricityprior to the exhaust contacting the muffler-catalytic converter unit142, That is to say, the turbo-generator 128 c may be positioned betweenthe engine 128 and unit 142. This configuration functions to protect themuffler-catalytic converter unit 142 from damage due to the extremelyhigh-temperatures of the exhaust that is output from the engine, thusextending the life of the unit 142.

For example, the exhaust may exit an exhaust manifold (not shown in FIG.5) of the engine 128 at approximately 1,600° F. At this temperature theexhaust may damage elements of the catalytic converter 143 a within unit142. Accordingly, to prevent such damage the inventors provideembodiments that places the turbo-generator 128 c in between thecatalytic converter 143 a and the engine 128. Unlike the catalyticconverter 143 a, the turbo-generator 128 c, may be operable to receivethe exhaust at this temperature without being damaged. Accordingly, theexhaust from the exhaust valve may flow through vanes (not shown) of theturbo-generator 128 c.

Upon exiting the turbo-generator 128 c, the temperature of the exhaustis approximately 1,200° F. as is flows to the muffler/catalyticconverter 142. Accordingly, in one embodiment the temperature andpressure of the exhaust may be reduced by passing the exhaust throughthe turbo-generator 128 c prior to passing to the unit 142. It should benoted that while temperatures at 1,500° F. may damage the catalyticconverter 143 a, converters provided by the present invention mayoperate without risk of damage between 600 and 1,200° F., with anoptimal temperature of 800° F.

In sum, in embodiments of the invention the unit 142 that houses thecatalytic converter 143 a may be configured to be positioned within adistance from the engine 128 where the temperature of the exhaustoptimizes the operation of the catalytic converter 143 a.

Referring now to FIG. 6, there is depicted an enlarged view of anexemplary muffler-catalytic converter unit 142. Upon receiving theexhaust, the catalytic converter section 143 a of unit 142 (“converter”for short) may be operable to convert toxic gases (e.g. oxides ofnitrogen (NOx), carbon monoxide) in the exhaust to substantiallynon-toxic gases (nitrogen, hydrocarbons, carbon dioxide) as well asconvert the exhaust into additional heat that may be absorbed by thewater 120 a in the vessel 120 surrounding the converter 143 a. In anembodiment, section 143 a may comprise a ceramic structure having layerscoated with one or more of a metal catalyst, such as platinum, rhodiumand/or palladium, for example. As exhaust enters converter 143 a, it mayimpact a first so-called “reduction” layer comprising platinum andrhodium. This layer functions to reduce NOx in the exhaust by convertingNO or NO2 molecules in the exhaust to nitrogen. Thereafter, the exhaustmay impact a second or “oxidation” layer comprising palladium orplatinum that functions to reduce unburned hydrocarbons and carbonmonoxide through oxidization (burning) to carbon dioxide and water.

In some embodiments the converter 143 a may further comprise an oxygensensor that may be operable to detect a level of oxygen in the exhaustand send signals to a control section (not shown in figures) in order toensure that a proper stoichiometric balance of treated exhaust isachieved and maintained to ensure appropriate reduction of toxic gaseswithin the exhaust.

In an embodiment, the converter 143 a may be configured as honeycombedlayers or layers of ceramic beads, for example.

After the exhaust is treated in converter 143 a it may flow to themuffler section 143 b (“muffler”). In an embodiment, the muffler 143 bmay operable to operable to reduce a level of sound generated by theengine 128 and exhaust gases, for example, to less than 60 dB. Suchsound reduction is desirable in order to place the system 100 within ahouse or dwelling 200. Said another way, absent the muffler 143 b, theengine 128 may generate sound at a level that would be irritating to theinhabitants of the house or dwelling 200. Further sound reduction may beachieved by embedding the muffler 143 b within the storage vessel 120such that any sound that is not reduced by the muffler 143 b may bedampened or otherwise reduced by the water within the vessel 120, In anembodiment the level of sound escaping the vessel 120 may be less than60 dB, for example. Yet further, because the muffler 143 b is configuredwithin the vessel 120 it is less likely to be exposed to conditions(air) that would lead to its corrosion. Thus, it is expected that theuseful life of the muffler is lengthened by embedding it within vessel120. In an embodiment, the muffler 143 b may be made from a stainlesssteel, for example.

As mentioned previously the unit 142 may be embedded within water 120 awithin the vessel 120 in order to transfer heat from such components tothe water 120 a in order to capture energy in the form of heat from theexhaust. It should be noted that when the converter 143 a that is a partof unit 142 is so embedded, the temperature of the converter 143 a mayeventually equal the temperature of the water 120 a inside the vessel120. In an embodiment, this allows the converter 143 a to be moreefficient than existing converters. In more detail, during operation ofthe engine 128 the temperature of the water 120 a in the vessel 120 maybe in the range of 100° to 160° F. Accordingly, the embedded converter143 a will be at the same temperature at some point (or, at least ahigher temperature than ambient). In an embodiment, the converter 143 amay be operable to reach an optimum operating performance once it hasreached an optimum operating temperature. Accordingly, because thetemperature of embedded converter 143 a may be maintained at an elevatedtemperature the converter 143 a may reach (and maintain) an optimumoperating temperature more quickly than converters that are not soembedded. In an embodiment, because the converter 143 a can operate atan optimum operating temperature it may be able to more effectivelyremove toxic gases and elements from the exhaust within piping 130.

In an embodiment, the unit 142 may be configured to be easilyreplaceable. For example, in one embodiment the unit 142 may be replacedby removing some or all of the exhaust heat exchanger 130 and liftingthe unit 142 out of the sub-system 101.

Continuing, upon being treated by the unit 142 the exhaust may flow tothe exhaust heat exchanger that may be operable to transfer heat withinthe exhaust gases to water 120 a within the vessel 120. In an embodimentthe heat exchanger 130 may comprise a plurality of coiled piping (i.e.,coils) that are embedded in water 120 a within vessel 120. The coils 130may comprise a thermally conductive material, such as stainless steel,for example.

In an embodiment, as the heated exhaust flows through coils 130 it heatsthe coils 130 which in turn heat the surrounding water 120 a. Thus, heatis transferred from the exhaust into the water 120 a. Thus, thesub-system 101 can be said to capture energy in the form of heat thatwould ordinarily have been lost if the exhaust was simply discharged tothe atmosphere outside of the dwelling or house 200. The water 120 athat has been heated may be used as hot water for inhabitants (viaplumbing and appliances) of the dwelling or house 200.

FIG. 5 further depicts exhaust output piping 120 b and an exhaustcondensation drain 120 c. In an embodiment, after the exhaust exits thecoils 130 it may enter the piping 120 b and be safely expelled orotherwise output to the atmosphere or environment exterior to thedwelling or house 200. As the exhaust traverses the piping 120 b it mayundergo additional cooling. Accordingly, some of the gases within theexhaust may be converted to a liquid and flow back down the piping 120 btowards the bottom of the piping 120 b. In an embodiment, the piping 120b and drain 120 c may be configured to allow such liquid to escape thebottom of piping 120 b through drain 120 c.

As noted previously, the sub-system 101 may be operable to capture heatthat would otherwise be wasted from both the exhaust and from the engine128. We now turn to a discussion of the later.

Referring again to FIG. 5, sub-system 101 may further comprise a pump132 a that may be operable to provide a coolant (e.g., water) at adesired temperature and pressure to the engine 128.

As the coolant absorbs heat from the engine 128, the coolant flows awayfrom the engine 128 via coolant heat exchanger 132 (e.g. coiled pipingor coils) that may be operable to transfer heat from the coolant to theliquid 120 a within the vessel 120. In an embodiment, coils 132 maycomprise an exemplary, thermally conductive material, such as stainlesssteel.

Similar to coils 130, as heated coolant flows through coils 132 it heatsthe coils 132 which in turn heat the surrounding liquid 120 a. Thus,heat is transferred from the coolant into the water 120 a. Thus, onceagain the sub-system 101 can be said to capture energy in the form ofheat that would ordinarily have been lost if the heat from the coolantwas simply discharged. The water 120 a that has been heated may be usedas hot water for inhabitants (via plumbing and appliances) of thedwelling or house 200.

Once the coolant has travelled through the entire set of coils 132 itmay enter the pump 132 a prior to being re-introduced into the engine128.

Accordingly, the sub-system 101 captures or recovers heat from both theexhaust and coolant.

Backtracking somewhat, the sub-system 101 depicted in FIG. 5 may furtherinclude additional features that make the sub-system 101 highlyefficient and/or substantially noise free. For example, as shown thesub-system 101 may further comprise thermo-acoustic insulation 144(e.g., insulating foam) configured inside the internal surface of thetop section or cowling 101 a of sub-system 101. In an embodiment, thecowling 101 a may be configured to cover the top and sides of the engine128 and functions to prevent outside contaminants from interfering withthe operation of the engine 128. In addition, the insulation 144functions to absorb or otherwise prevent sounds emanating from insidethe cowling 101 a due to, for example, operation of the engine 128, fromescaping the cowling 101 a and causing irritation to inhabitants of thedwelling or house 200 in which the system 100 is installed. Yet further,the insulation 144 functions to prevent air 121 b within the cowlingfrom escaping, and instead the air 121 b is drawn into the engine 128through air intake section 113 b. In an embodiment, the air intakesection 113 b may comprise a filter (not shown) that functions to removecontaminants in the air that might otherwise cause the engine 128 tomalfunction if the contaminants were not so removed. As depicted in FIG.5, the air intake section 113 b may be positioned so that external air121 c from outside the sub-system 101 that is drawn into the cowling 101a through an external make-up air supply section 113 a (e.g., piping) isfirst able to flow over the engine 128 and generators 128 a,b in orderto provide additional cooling of the engine 128 and generators 128 a,bbefore such, now heated air 121 b is taking into the intake air section113 b. Said another way, rather than position the air intake section 113b immediately next to the supply section 113 a, which would then directair 121 c into the engine 128 to be mixed with fuel and combusted, butwould make the air 121 c unavailable to cool the engine 128 andgenerators 128 a,b the air intake section 113 b is positioned at adistance from the supply section 113 a so that air 121 c can first flowover the engine 128 and generators 128 a,b, in effect transferring someof the heat from the engine 128 and generators 128 a,b into the flowingair 121 c. The now heated air 121 b may then enter the intake section113 b. In an embodiment, in addition to positioning the intake airsection 113 b so that external air 121 c may flow over and cool theengine 128 and generators 128 a,b, such a position also allows for theair 121 c to be heated, in effect allowing “pre-heated” air 121 b toenter the engine 128 via the air intake section 113 b. The ability toinput pre-heated air functions to make combustion of the fuel moreenergy efficient.

As noted above, the supply section 113 a may comprise piping (e.g., apolyvinyl chloride material, “PVC”). In an embodiment, the openings 113d that receive the piping 113 a (as well as exhaust piping 120 b whichmay also comprise PVC) may be sealed using, for example, a gasketing andlatch configuration. In addition, due to the operation of the engine128, air in the cowling 101 a will be drawn into the engine 128 causinga pressure gradient inside the cowling 101 a to form. In an embodiment,this pressure gradient may prevent leakage of any air from inside thecowling 101 a to the outside surroundings.

As noted, provided the engine 128 is operating, air within the cowling101 a be drawn from the supply section 113 a, over the engine 128 andgenerators 128 a,b and into the air intake section 113 b. However, whenthe engine 128 is not operating (or not operating correctly) asufficient amount of air may not be drawn into the cowling 101 a via thesupply section 113 a. Should this situation occur, the temperature andpressure of the air that is already inside the cowling 101 a that hasbeen heated by the engine 128 may rise to level that may adverselyaffect the operating efficiency of the engine 128. To mitigate such anaffect, in an additional embodiment subsystem 101 may comprise one ormore fans 113 c (“fan”). In an embodiment, the fan 113 c may bepositioned in-line with the top of the exhaust piping 120 b, forexample. The fan 113 c may be operable to create a negative pressure inorder to draw air out of the cowling 101 a in order to reduce theaffects discussed above thus, allowing the engine 128 to functionproperly.

The sub-system 101 may include additional components. For example, afuel injector 128 d that functions to control the amount of a fuelsource that is injected into the engine 128 to be mixed with air intakeand an intake air valve train 128 e are shown in FIG. 5.

As noted previously, the sub-system 104 may be operable to store energy.This energy may be used by an inhabitant of the dwelling or house 200or, alternatively, be delivered back to an electric utility's grid inreturn for compensation or credits, for example.

Yet further, in an embodiment, a utility may install controls (not shownin figures) that permit the utility to request and receive energy storedwithin sub-system 104 as needed. For example, it is known that manyutilities must pay (other utilities, or energy source providers) asubstantial premium to supply electrical energy to residential andcommercial customers during “peak” energy time periods (e.g. wheneveryone turns their air conditioners on over the same time periodduring the summer months). This premium may amount to 25% or more of autilities' yearly cost of providing electricity. In contrast, theembodiments of the present invention when combined with requiredcontrols allows such a utility to request and receive additional powerfrom energy storage sub-section 104 instead of another utility at alower cost.

Still further, embodiments of the invention may lower a utility's costof producing electricity in yet another way. For example, it is knownthat a substantial amount of energy from an energy source (coal) is lostbetween the time the energy source is used by a utility to generateelectricity at an operating plant and the time the energy is actuallydelivered to a remote customer. By some estimates, 65% of the energygenerated is lost by the time it is delivered to a customer'straditional heating and electrical system. In comparison, experimentscompleted by the inventors demonstrate that systems provided by theinvention, such as system 100, installed at a location 200 where theheat and electricity will be utilized have the capability of deliveringapproximately 60% more energy than traditional heating and electricalsystems.

The following description provides a more detailed description of anexemplary engine that may be used as a part of an exemplary system inaccordance with an embodiment of the invention.

Exemplary Four-Stroke Opposed Piston Engine

Certain novel aspects of the present invention, with regard to anexemplary engine for example, are presented below as well as in the '711application. Further, U.S. Pat. Nos. 7,004,120 and 7,779,795, and U.S.patent application Ser. Nos. 15/442,617 and 13/633,097 are related tothe present invention, of which the teachings of each document areherein incorporated by reference in their entireties.

Referring to FIG. 7, an opposed piston engine 500 (or 128 in FIG. 5) maycomprise an engine housing 505 (see FIG. 7 for example) containing afirst cylinder 510 and a second cylinder 510′ (see FIG. 10, forexample). A first pair of opposed pistons 520 and 530 are housed withinthe first cylinder 510 (see FIG. 11, for example). A second pair ofopposed pistons 520′ and 530′ are housed within the second cylinder510′. Although discussion is directed to the first cylinder 510containing pistons 520 and 530, the same discussion may be applied withregard to second cylinder 510′ and opposed pistons 520′ and 530′ (and/orvice-versa).

Opposed pistons 520 and 530 are connected via respective connecting rods522 and 532 to respective crankshafts 540 and 542 mounted in enginehousing 505 as described in U.S. Pat. No. 7,004,120. Pistons 520 and 530reciprocate within cylinder 510 to rotate the crankshafts, in a mannerknown in the art. Each associated crankshaft and/or connecting rod isconfigured to aid in providing a predetermined stroke length to itsassociated piston residing within the cylinder. The opposed first andsecond pistons 520 and 530 may be of a relatively standard design andmay have predetermined lengths and predetermined diameters.

In one embodiment, the stroke length of each of pistons 520 and 530 maybe about 3 inches. Thus, the total difference between the spacing of thepistons at closest approach to each other (i.e., at “top dead center”)may range from 0 inches to 0.25 inches, and more preferably from about0.05 inches to 0.2 inches, and the maximum spacing of the pistons duringthe engine cycle (i.e., at “bottom dead center”) is about 4-7 inches,and more preferably about 6 inches. As will be apparent to one ofordinary skill in the art, these distances may be altered depending onspecific design criteria.

If desired the length and timing of the engine's stroke may be adjusted(to substantially equal lengths) for controlling the spacing between thepiston faces, thereby providing a means for adjusting the compressionratio and generally providing a predetermined degree of compression forheating intake air to facilitate combustion of a fuel injected orotherwise inserted into the combustion chamber. The piston lengths maybe geometrically determined in accordance with the piston stroke lengthand the lengths of apertures (described below) formed in the cylindersthrough which flow exhaust gases and air for combustion. In oneembodiment, each piston cap 524 and 534 (see FIG. 9) may comprise asandwich of two sheets of carbon fiber with a ceramic center. The pistoncaps 524 and 534, which are exposed to a combustion event, may be formedso that when the two piston caps 524 and 534 meet in the center of thecylinder 510 they preferably form a somewhat toroidal,hour-glass-shaped, or otherwise-shaped cavity as the combustion chamber521 (see FIG. 11, for example). In an embodiment, only the ceramic coresof the piston caps 524 and 534 actually come into contact with thestationary cylinder wall.

Each piston should have a length from the piston fire ring to the capsuitable for keeping the piston rings out of the cylinder opening(s) 510a. The piston caps 524 and 534 each have a diameter roughly equal to theinterior of the associated cylinder, and may be made of carbon fiber,ceramic, or any other suitable material to aid in minimizing thermalinefficiencies during engine operation.

In an embodiment utilizing a delivery conductor and ground conductor forspark generation (as described in U.S. Pat. No. 7,448,352), the face ofeach piston may also include a slot(s) or groove(s) formed therein andconfigured for providing a clearance between the piston face and thedelivery and ground conductors, as the pistons approach each otherwithin the cylinder.

FIGS. 12 and 13 each show exemplary side and plan views of a gear train512. As shown, gears 512 a, 512 b connected to crankshafts 542, 540 (notshown in FIGS. 12 and 13) respectively, rotate at crankshaft speed butare reduced in size to serve as reducing gears. Thus, the rotationalspeeds of the gears 512 c and 512 d (and the rotational speeds of thecam discs 520, 522, 520′, and 522′ to which they are connected) may bereduced to one half of the crankshaft speed.

Various elements of a vehicle and/or engine system (for example, an oilpump or coolant circulation pump) may be operatively coupled to, andpowered by, the gear train 512, via the gears in the gear train itselfor via shafts and additional gears operatively coupled to the gear train512.

Exemplary housing components of an exemplary engine are illustrated inFIG. 11. FIG. 11 illustrates the cylinders 510, 510′ comprising cylinderopenings 510 a and 510 b, and spark plug openings (only the former isshown in FIG. 11).

Referring still to FIG. 11, there is illustrated an exemplary interfaceof two opposed pistons whereby the piston cap interface at top deadcenter (TDC) forms a toroidal combustion chamber 521. The valves 525 and527 may also be seated or configured within opposed detents or cavities520 f, 530 f, 520 f, 530 f′ formed as a part of the top and bottom ofthe pistons, that when combined, function to seal a valve/pistoninterface during the four-stroke process, and during operation of valvesas they open and close.

It should be understood that the preceding is merely a detaileddescription of various embodiments of the invention and that numerouschanges to the disclosed embodiments can be made in accordance with thedisclosure herein without departing from the scope of the invention. Thepreceding description, therefore, is not meant to limit the scope of theinvention. Rather, the scope of the invention is to be determined onlyby the appended claims and their equivalents.

We claim:
 1. A combined heat and power system comprising: an energygeneration sub-system comprising, a replaceable engine connected to aplurality of generators and a turbo-generator, the generation sub-systemfurther comprising a catalytic converter, embedded in a vessel forstoring liquid heated by waste heat from the engine, and configured tobe positioned within a distance from the engine, where a temperature ofexhaust gases optimizes the operation of the catalytic converter; and anenergy distribution sub-system comprising, coils operable to circulateheated coolant received from the energy generation sub-system, and, fansoperable to direct air over the coils to heat the directed air, andoperable to distribute the heated air.
 2. The system as in claim 1further comprising a muffler embedded in the vessel and operable toreduce a level of sound from the engine and the exhaust gases.
 3. Thesystem as in claim 1 further comprising a coolant heat exchangeroperable to transfer heat from coolant to the liquid within the vessel.4. The system as in claim 1 further comprising an air intake sectionconfigured to be positioned so that external air from outside an energygenerating sub-system is drawn into a cowling and over an engine andgenerators in order to cool the engine and pre-heat the air;
 5. Thesystem as in claim 1 further comprising an air intake section configuredto be positioned so that external air from outside an energy generatingsub-system is drawn into a cowling, having thermo-acoustic insulationconfigured inside the cowling to prevent sounds emanating from insidethe cowling from escaping the cowling, and over an engine and generatorsin order to cool the engine and pre-heat the air.
 6. A method forproviding heat and power comprising: generating electricity and exhaustgases from an engine; storing a liquid, heated by waste heat from theengine, in a vessel; embedding a catalytic converter in the vessel at aposition where a temperature of the exhaust gases optimizes theoperation of the catalytic converter; and circulating heated coolantthrough coils and directing air over the coils to heat the directed air,and distributing the heated air.
 7. The method as in claim 6 furthercomprising embedding a muffler in the vessel to reduce a level of soundfrom the engine and the exhaust gases.
 8. The method as in claim 6further comprising transferring heat from coolant to the liquid withinthe vessel.
 9. The method as in claim 6 further comprising positioningan air intake section so that external air is drawn over an engine inorder to cool the engine and pre-heat the air.
 10. The method as inclaim 6 further comprising preventing sounds emanating from inside acowling from escaping the cowling.